Tool and Die Maker Course

Lesson 1 • Classification of Die Types

Distinguishes stamping, forging, casting, and extrusion dies by function. Provides a framework for selecting the correct die category.

Lesson 2 • Introduction to Die Technology

Covers the historical development and industrial role of dies. Establishes vocabulary used throughout the course.

Lesson 3 • Die Components and Assemblies

Identifies standard components such as punches, die blocks, and guide pins. Connects component knowledge to assembly logic used in later chapters.

Lesson 4 • Safety and Regulatory Fundamentals

Introduces machine guarding, lockout procedures, and workplace safety standards relevant to die operations. Establishes a safety mindset carried through all subsequent chapters.

Lesson 1 • Tolerance Stack-Up Analysis

Explains worst-case and statistical methods for analysing cumulative tolerances. Prevents fit failures in assembled die components.

Lesson 2 • CAD Drawing Interpretation

Bridges paper drawing skills to 2D and 3D CAD file reading. Prepares learners for digital design tools introduced in the next chapter.

Lesson 3 • Dimensioning Standards and Practices

Covers linear, angular, and chain dimensioning conventions. Ensures learners apply correct dimensioning when producing die drawings.

Lesson 4 • Geometric Dimensioning and Tolerancing

Introduces GD&T symbols, datum references, and tolerance zones. Enables precise control of die component fit and function.

Lesson 1 • Assembly Modeling and Constraints

Covers mate types, assembly constraints, and interference detection. Ensures all die components fit correctly before physical fabrication.

Lesson 2 • Drawing Generation and Documentation

Produces fully annotated manufacturing drawings from 3D models. Completes the design-to-documentation workflow required for die fabrication.

Lesson 3 • Sheet Metal and Formed Part Modeling

Teaches flat pattern development and bend allowance calculations within CAD. Directly informs die geometry for stamping and bending operations.

Lesson 4 • Modeling Die Blocks and Punches

Guides creation of die block cavities, punch profiles, and clearance geometry. Connects modelling precision to functional die performance.

Lesson 1 • Drawing and Deep Drawing Dies

Explains blank holder force, draw ratio, and ironing in deep drawing operations. Connects process parameters to die geometry decisions.

Lesson 2 • Blanking and Piercing Die Design

Covers punch-to-die clearance, shear angle, and cutting force calculations. Forms the analytical foundation for all cutting die designs.

Lesson 3 • Bending Die Design

Addresses springback compensation, bend radius limits, and V-die versus wiping die geometry. Enables accurate bent-part production.

Lesson 4 • Progressive Die Strip Layout

Teaches station sequencing, pilot hole placement, and carrier strip design for progressive dies. Optimises material utilisation and part quality.

Lesson 1 • Impression Die Design

Covers blocker, finisher, and trimmer die cavity design for closed-die forging. Ensures complete fill and dimensional accuracy in forged parts.

Lesson 2 • Cold Forging and Coining Dies

Addresses high-pressure tooling requirements, surface finish demands, and die life in cold forming. Distinguishes cold die design from hot forging approaches.

Lesson 3 • Thermal and Wear Management

Covers die preheating, cooling channel design, and wear-resistant coatings for forging dies. Extends die service life under thermal cycling.

Lesson 4 • Extrusion Die Design

Explains porthole, flat-face, and back-extrusion die configurations. Connects die geometry to extrudate shape accuracy and surface quality.

Lesson 1 • CNC Machining and Toolpath Planning

Covers 3-axis and 5-axis CNC strategies, cutter selection, and feeds and speeds for die steels. Enables efficient and accurate die cavity machining.

Lesson 2 • Conventional Machining for Dies

Reviews milling, turning, grinding, and jig boring as applied to die components. Establishes baseline machining knowledge before CNC methods.

Lesson 3 • Electrical Discharge Machining

Explains sinker EDM and wire EDM processes for complex die features. Addresses electrode design, flushing, and surface integrity.

Lesson 4 • Die Finishing and Polishing

Addresses bench grinding, lapping, and polishing sequences to achieve required surface finishes. Directly affects part quality and die release.

Lesson 1 • Production Approval and Sign-Off

Covers first-article inspection, capability studies, and approval documentation. Formally qualifies the die for production release.

Lesson 2 • Die Correction Techniques

Addresses metal removal, welding, shimming, and insert replacement to correct die defects. Builds practical adjustment skills used in production environments.

Lesson 3 • Tryout Planning and Setup

Covers press selection, die installation, and initial setup parameters for first-hit tryout. Reduces costly trial iterations through structured preparation.

Lesson 4 • Process Window Validation

Establishes acceptable ranges for press speed, lubrication, and blank dimensions. Confirms robust production conditions before full launch.

Lesson 1 • Wear Monitoring and Measurement

Covers punch and die wear measurement, surface degradation assessment, and wear rate tracking. Enables data-driven maintenance decisions.

Lesson 2 • Die Storage and Handling

Covers rust prevention, protective coatings, and safe transport practices for stored dies. Preserves die condition between production runs.

Lesson 3 • Corrective Maintenance and Repair

Addresses regrinding, insert replacement, and weld repair procedures for worn die components. Restores die performance to specification.

Lesson 4 • Preventive Maintenance Programmes

Defines inspection intervals, lubrication schedules, and cleaning procedures for active dies. Prevents unplanned downtime and extends die life.